Error Proofing (Poka-yoke)

Error Proofing – A process improvement that reduces defects and eliminates the causes of errors

three pin

One of the tools in the Business Improvement tool-kit that will help us reach the goal of being defect free

  • Safety – Prevents personal injury
  • Quality – Prevents faulty products
  • Cost – Reduces non-value added activities
  • Confidence – Improves confidence in process capability

Error Proofing is often to referred to by the Japanese termPoka-yoke”, this quite simply means to design a process, product or behaviour in such a way that it cannot go together incorrectly.

One of the greatest examples of this is the standard 3 pin plug, as hard as you may try, it impossible to insert it into a 3 pin plug into socket incorrectly without breaking it.

Error Proofing

What does Error Proofing Do?

  • Stops the defect occurring !
  • Makes incorrect actions impossible to carry out
  • Makes it possible to distinguish between errors and defective materials
  • Ultimately makes inspection redundant

Types of Error Proofing

Quality does not come from inspection, but from the inputs and of the process process be it man, method, or machine. Anywhere in that chain that is an opportunity for error to occur must be addressed

So instead of looking for errors in work that has already been completed, all efforts should go into fixing the process as soon as possible so no further errors can occur. Be this through the introduction of physical barriers or to going back to design process and designing out the ability to make wrong.

Business Benefits of Error Proofing 

poka yoke 1

  • Zero Defects – Consistent high quality output 
  • Zero Waste – Lower costs
  • Zero Delays – On Time Delivery
  • Zero Injuries – Designed for safety
  • Zero Complaints – High levels of customer confidence and trust

For further information or to arrange a Skype call please to discuss your needs contact – we will get back to you within 24 hrs

To book your FREE Consultation call 07977 147130 or email
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